KR970003357B1 - Cementless lamp bulb and base combination - Google Patents

Abstract

None.

Description

Lamp Bulb and Base Assembly without Cement

1 is a side view of a car headlamp

2 is a bottom view of the lamp of FIG. 1

3a and 3b show side and front views, respectively, of the half-holder element of the lamp.

4A and 4B are a bottom view and a cross-sectional view of the base sleeve of the first degree lamp, respectively.

5a to 5d are a cross-sectional view, a side view, a plan view and a bottom view of the base plug of the first degree lamp, respectively

6A and 6B are side and longitudinal cross-sectional views, respectively, of the contact blades.

The present invention relates to a small halogen incandescent lamp for automobiles, and more particularly to a structure for mounting a bulb of a lamp to a lamp base without using cement.

This type of lamp, consisting of a base assembly of metal and plastic, is especially used for automotive headlights. For example, the German Federal Utility Model Application No. 8201536 describes such a car headlight, whose plastic base (dish element) has a very complex design. However, the optical quality of the headlights depends heavily on the quality of such components, which should have as little impact as possible. For this reason, European Patent Application No. 85201643 proposes a base made of a synthetic material and formed of two parts connected by ultrasonic welding.

One of the two parts is formed as a hollow cylinder and the remaining part forms its base or bottom wall. The hollow cylinder portion is mechanically connected to the base sleeve by notches and protrusions that surround and engage the cylindrical base sleeve. The terminal tab is connected to the bottom wall by ultrasonic welding.

SUMMARY OF THE INVENTION The present invention provides a base composed of a metal part and an insulator part having a simple configuration and capable of reliable connection in a lamp as described above.

This object is achieved by the construction described in the specific part of claim 1. Still other advantages and features are apparent from the description of the dependent claims.

The lamp bulb and base assembly of the present invention requires less material than prior art structures. In addition, ultrasonic welding is not required during manufacturing, so the required energy is substantially reduced. And individual assembly steps are possible with very short assembly times.

Heat resistant plastic materials that can be thermoplastics can be used as insulating materials because of their ease of manufacture and low weight.

A preferred means for the mechanical connection between the base sleeve and the bottom of the base is to provide a simpler configuration by means of a rotary bayonet connection, as described in EP 85201643, between the metal sleeve and the two composite parts. Obtained by interaction. To this end, the cylindrical base sleeve is provided with a flange or corner bent inward at the end opposite the bottom of the base or base plug. The width of this flange is about 10% of the diameter of the base sleeve to obtain sufficient mating area for precise alignment of the base plug. This large flange makes it difficult to properly position the current supply leads.

To form the flange element, the bent corner portions of the base sleeve are formed by individual ring portions spaced apart from each other at slightly larger intervals than the peripheral length of the stopnose of the base plug. Thus, during assembly, the base sleeve can be seated on a flat area of the base plug in such a way that the stopnose first enters the gap between the flange elements and seats into the base sleeve. Four flange elements and stop noses are suitable, resulting in a sufficient number of joining surfaces as well as as many attachments as possible.

The base sleeve then rotates relative to the base plug so that the stopnose is engaged with the flange element. Thus a particularly reliable and inseparable connection relationship can be tolerated.

For example, the thickness of the flange element is chosen to be greater than the spacing between the flat joining area and the bottom side of the stopnose so that during rotation the flange element is clamped between the flat joining area and the bottom side of the stopnose to secure the connection. Force is obtained.

Each stopnose is tilted slightly to facilitate the rotation above. In rotation, some ridges on the flat mating area can act as stop members. The height of this ridge is carefully selected to ensure that the rotation of the flange element across the ridge is difficult and ensures its function as a stop member.

The ridge is preferably given another function. The possibility of horizontal movement of the base sleeve relative to the base plug in rotation should be ruled out. It is clear that the outer diameter of the ring collar must exactly match the inner diameter of the circle formed by the flange element. However, this creates a greater difficulty in mounting the base sleeve over the base plug (incorrect alignment) and makes the rotation impossible due to large friction. The centering of the base sleeve over the base plug is very important for the positioning of the lampbulbs, so the ridges can be used to adjust the length of the outer circumference that is used as an adjustment stop for accurate centering of the base sleeve relative to the base plug. It must be formed as a ring portion having. The base sleeve itself provides an inwardly bent edge region between the flange elements, but the width of the edge region is less than the width of the flange element and its inner diameter is formed after each corner region as a ring portion after rotation. It is chosen to fit precisely along the outer perimeter of the ridge.

For relatively small headlamps (called H1 or H3 lamps) with only one filament, it is desirable that the base plug be formed into a rigid, cylindrical body that is easy to manufacture and simple. Larger mass is not desirable against hollow base plugs. The rigid plug, on the other hand, facilitates the formation of a collar whose flat engagement surface provides a large surface area for the flange element of the base sleeve. Ultrasonic welding of metal parts (for example, described in EP-A 85201643) in plastic materials (thermoplastic materials) previously implemented, or by inserting and deforming metal parts in thermocompression parts (see DE-GM 8201536 for German applications) ) No work (usually used for larger H4 lamps) is required. On the other hand, the entire body portion of the plug element can be used to make a pure mechanical connection. This saves time in manufacturing and solves the problem of footprint in small lamps.

In particular, a simple connection of this type can also be obtained for the contact blades. At its end away from the bulb, the base plug has slits in the longitudinal axis, which are adapted to the width of the contact edge and accommodate about one third of the contact edge length. The contact blades themselves have a toothed projection formed on their narrow sides and the projections can be received in the slit such that the projections of the contacting blades engage into the slits and the contacting blades are securely seated therein.

The metal holder for fixing the press seal of the bulb can be used similarly to the embodiment described in German Utility Model Application DE-GM 8522797. Unlike the prior art in which the metal holder is connected to the plastic base, the metal holder is welded to the metal base sleeve.

Embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

1 and 2 show standard H3 automotive lamps. This lamp has a cylindrical bulb 1, which is made of tempered glass or quartz glass and has an exhaust tip 2 integrally formed at one end thereof. The other end of the bulb 1 is sealed by the press seal 3 by vacuum sealing. In the bulb 1, the coil tungsten filament 4 is held by two molybdenum lead wires 5, 6. The lead wires 5 and 6 are sealed directly into the press seal 3. The bulb is filled with an inert gas and a halogen additive. The press seal 3 is supported by a holder 7 made of metal (stainless steel) composed of two identical holder half powders 8. The holder element 7 is attached to the press seal 3 by a protrusion formed on the wide face of the press seal which is engaged in a rectangular hole in the holder half body 8 (see FIG. 3). The holder element 7 is received into a metal base sleeve 9 (made of stainless steel). The base sleeve 9 is formed as a hollow cylinder and on its inner surface four pointed engaging bumps 10 are formed along the circumference, to which the holder element 7 is attached by laser welding. In addition, the base sleeve 9 is provided with a ring 11 for adjustment or positioning, which is formed as a whole at an end facing the bulb. The adjusting ring 11 is formed with notches of two different shapes in order to position the lamp accurately into the reflector.

The base plug 12 made of plastic is installed at the end of the base sleeve away from the bulb. This base plug consists of a cylindrical body of approximately the same diameter (14 mm) as the base sleeve. In contrast, the base diameter of the H4 lamp with two filaments is significantly larger (20 mm). A similar difference in size is the bulb diameter of 12.5mm for H3 lamps and 17mm for H4 lamps. Two contact blades 13 (made of stainless steel or non-ferrous metal) are inserted into the ends of the base plug 12 apart from the bulb parallel to the lamp axis. Each contact blade 13 is formed with an eye 14 that is bent at an angle of 90 °, and is connected to be electrically connected to an end portion of the lead wire extending from the press seal 3. A semicircular eye 14 is secured into a similarly shaped recess 15 in a rectangular recess 16 at one end of the base plug 12 for better protection from mechanical damage. The individual parts of the holder for the glass bulb are described in detail below.

3A and 3B show an enlarged view of one of the half powders 8 of the holder element 7. The holder half body 8 has a rectangular base body 17 which abuts the wide one side of the press seal which is fixed by two rectangular openings 18 cooperating with the protrusion on the plastic seal. One side of the base body 17 has a shoulder 19 and three spaced apart tongues 20 at an angle. On the opposite side, the base body 17 has an elongate portion 21 in which two straps 22 are formed horizontally so as to engage with the tongues of the second same holder half powder. By this tongue and strap two identical holder halves are joined to form a cuff that completely encloses the press seal, whereby in each case the tongue from one holder halves is bent over the extension of the other holder halves And the strap is bent into the shoulder with the tongue (see also FIG. 1).

The base body 17 has an extension 23 which is bent back 180 ° out of the face opposite the bulb. The elongation 23 represents a portion of a circle having a radius of curvature that terminates at the conical bulging out of elastic apron 24 and thereby matches the inner curvature radius of the cylindrical base sleeve 9 at its end. Preferably, this end region is bifurcated into two flaps 25 with reinforcing rings. The completed holder element 7 forms four partially circular legs which are welded onto the joining bump 10 on the base sleeve 9.

4A and 4B show the structure of the base sleeve 9. In the base sleeve 9, the coupling bump 10 and the positioning ring 11 as described above are provided at ends opposite to the bulb. The positioning ring 11 acts to position the lamp into the headlight opening and comprises two diametrically opposed notches of different shapes of semicircular and rectangular notches 26a and 26b. At the end away from the bulb, the base sleeve 9 has an acute flange portion 27 lying on a plane intersecting the axis of the lamp. This flange is very narrow. Its inner diameter is only slightly (3%) smaller than the inner diameter of the base sleeve 9 (indicated by the broken line). The four flange elements 28 are part circumferential portions with a radial width of about 1 mm and are formed integrally on the flange portion 27 by symmetrical arrangement and extend the flange portion further into the base sleeve 9. The inner diameter of the theoretical circle defining the outer line of the flange element is about 80% of the outer diameter of the base sleeve 9. The ratio of the length of the flange element to the length of the intermediate free region of the flange is about 3: 1. The flange element 28 has a thickness equal to the thickness of the wall of the base sleeve 9 (0.5 mm) and serves to attach the base sleeve 9 to the base plug 12.

As a result, as shown in Figs. 5A-5D, the base plug 12 is provided with a circumferential collar 30 extending in the axial direction at the end of the cylindrical body 29 facing the base sleeve 9. The outer diameter of the collar 30 is selected to be reduced to about 80% of the diameter of the cylindrical body 29 and to fit smoothly with the inner diameter of the flange element 28 of the base sleeve 9. The collar 30 is divided into eight free protrusions 31 and 32 (FIG. 5C) with alternating short protrusions 31 and long protrusions 32. The four short collar protrusions 31, which are about three times smaller in the peripheral length than the other four portions 32, have an attachment protrusion or stop-nose 33 that protrudes outwardly inclined in a ramp shape. The height of the ramp is formed at the bottom edge of the stopnose. The distance of the lower edge of the stop-noise 33 from the area 34 called the engagement surface of the body is 0.45 mm and thus significantly less than the thickness of the flange element 28 of the base sleeve 9.

The lower edge is slightly bent upward at one side to facilitate stopping and engagement of the flange element 28 between the engaging surface 34 and the stop nose 33 lower edge. The upwardly inclined portion 35 extends to a slightly larger extent than the thickness of the flange element 28.

The raised or projected portion 36 in the form of a partial circle lies centered between the two short portions 31 out of the elongated collar portion 32 and is located on the engagement surface 34. The height of the protrusions or ridges 36 is about 0.2 mm. The radial width is chosen to closely match the inner diameter of the flange portion 27 of the base sleeve and thus to align the base sleeve. The peripheral length of the short collar portion 31, the peripheral length of the projection 36 and the peripheral length of each portion of the flange 27 are the stop nose 33 when the base sleeve 9 is seated on the base plug 12. (To a length of 2.7 mm) is coordinated to be secured into the parts of the flange. In relative rotation thereafter, the protrusion 36 is fully engaged into the free space between the flange elements 28 such that the protrusion 36 fits into the inner edge of the flange portion 27. The perimeter of the flange portion 27 should be slightly longer than the perimeter of the short collar portion 31 and the perimeter of the protrusion 36.

The rigid body 29 is formed with two reed-shaped shaft bores 37 so that the lead wires 5 and 6 can penetrate from the lamp bulb 1. A portion of the bore 37 length may be formed as the common recess 38. The bore 37 terminates into a semicircular recess 15 at the end of the base plug away from the bulb. The two recesses 15 are commonly located in the rectangular recesses 16 and are separated from each other by the ridges 39. On the narrow side of the recess 16, the axial slit 40 extends into the rigid body 29. The width and thickness of this slit match the width and thickness of the contact edge 13. The length becomes about 1/3 of the total length of the contact blade 13.

As mentioned above, the mechanical fixation of the contact blade 13 into the slit 40 is formed on the narrow side of the contact blade over about one third of its length (see FIGS. 6a and 6b). Made by 41. These protrusions 41 enter the slit and settle themselves therein. In addition, the eye 14 is punched and then bent from the flat portion of the contact blade 13 to be placed into the serrated projection of the contact blade 13.

Hereinafter, a manufacturing process of the lamp will be described. First, the holder element is mounted on a lamp without a base by placing two halves of the holder around the press seal and interconnecting them. On the other hand, the contact blade is inserted into the base plug. The base sleeve is then placed over the base plug and fixed in place by rotating the plug and sleeve relative to each other.

The lamp and base are now loosely attached and lead wires flow through the bore of the base plug. The positioning of the lamp bulb is then precisely adjusted to the extent that it can change the position of the lamp relative to the sleeve in three dimensions. The depth through which the holder penetrates into the sleeve may vary: the holder element and the sleeve can be rotated relatively and furthermore the tilt of the holder element relative to the sleeve can be adjusted.

The elastic properties of the four aprons extending from the coupling bumps and holder elements on the sleeve allow for precise adjustment. After the bulb and sleeve are correctly adjusted, laser spot welding is performed between the apron extension and the mating bumps to cause the bulb to be permanently adjusted into the sleeve. The end of the lead wire protruding beyond the eye is then cut off and a reliable electrical connection is made by tungsten-inert gas shield welding.

The invention is particularly suitable for small automotive headlamps with a single filament and a two-part metal-plastic base. However, it can also be used for other lamps with or without halogen. It is also suitable for use in lamps with two parts plastic base and / or larger automotive lamps with two filaments.

In this embodiment, the lamp may be configured as a wholly sealed base lamp. If necessary, potting compounds may be introduced into the recesses 38, and external potting compounds may be used to fill the cavities formed by the recesses 15 and the recesses 16.

Claims (17)

In the lamp bulb and base assembly which does not use cement, the press seal glass bulb 1 and the filament 4 having one end, the lead wires 5 and 6 extending out of the press seal, and the metal A two-piece base consisting of a base sleeve 9 made of metal and another base part made of an insulating material, and a holder element surrounding the press seal 3 of the bulb 1 and connected to the base sleeve 9 ( 7) and a contact element mounted to the base and electrically connected to the lead conductor, wherein the base sleeve 9 is formed of a cavity cylinder and at least two spaced flange elements 28 at the ends away from the bulb are symmetrical. In an inclined arrangement extends into the interior of the sleeve and at right angles to the axis of the lamp, another base portion being raised as a base plug 12 at the end of the base sleeve away from the bulb. And formed as a cylindrical rigid body 29, which is formed integrally on the circumference with an axial collar 30 at the end opposite the base sleeve and whose outer diameter is the diameter of the rigid body 29. Smaller than the outer diameter, the rigid body 29 includes at least two collar portions 31 having a stopnose 33 extending outwardly and engaged behind the flange element 28 of the base sleeve and with an individual portion 31. Cementless lamp bulb and base assembly, characterized in that it is predivided into The lamp bulb and base assembly according to claim 1, wherein the flange element (28) is formed as a partial circular cross section. 3. The lamp bulb and base assembly according to claim 2, wherein the peripheral length of the stop nose 33 is slightly smaller than the mutual spacing of the flange elements. The lamp bulb and base assembly according to claim 1, wherein the distance between the base sleeve and the stop nose 33 of the collar and the end of the rigid body 29 opposite is smaller than the flange element thickness of the base sleeve. 5. The lamp bulb and base assembly of claim 4 wherein the spacing is about 10% smaller than the thickness of the flange element. 5. The lamp bulb and base assembly according to claim 4, wherein the stop-noise (33) has a horizontally inclined surface (35). 2. The rigid body according to claim 1, wherein the rigid body has a flat engagement surface (34) formed at the end opposite the bulb and protrudes on the engagement surface out of the ring-shaped collar (30) and centered between the stop-noise (33). Lamp bulb and base assembly, characterized in that 36 is formed 8. The lamp bulb and base assembly according to claim 7, wherein the height of the projections (36) does not exceed one half of the distance between the engagement surface (34) and the stop nose (33). 8. The projection (36) according to claim 7, wherein the projection (36) is formed as a partially circular ring portion which abuts against the outside of the portion (32) of the collar (30) and its peripheral length is greater than the spacing of the flange elements (28). Lamp bulb and base assembly characterized by the small 8. The radial width of the projections (36) is smaller than the radial width of the flange elements (28), with an acute flange portion (27) extending into the area provided by the spacing between said flange elements, The lamp bulb and base assembly, characterized in that the radial width of the portion 27 is selected to abut the wide side of the protrusion 36. The lamp bulb and base assembly according to claim 1, wherein the contact element is formed by a contact blade (13) inserted into the longitudinal slit (40) at the end of the base plug (12) away from the bulb. 12. Lamp bulb and base assembly according to claim 11, characterized in that the contact blade (13) enters into the longitudinal slit (40) of the base plug with its serrated projection (41) at its narrow side. 12. The contact blade (13) according to claim 11, wherein the contact blade (13) has a bent eye (14) projecting at right angles therefrom and is fixed into the recess (15) at the base plug end away from the bulb, the eye being rigid body (29). Lamp bulb and base assembly, characterized in that it is connected to lead leads (5, 6) through the axial bore (37) in the 14. Lamp bulb and base assembly according to claim 13, characterized in that the recess (15) itself is located in the recess (16) at the base plug end away from the bulb. The outer diameter of the base sleeve 9 and the base plug 12 is approximately the same size, and the outer diameter of the ring-shaped collar 30 is about 80% of the outer diameter of the base sleeve and the base plug. Lamp bulb and base assembly characterized in that The lamp bulb and base assembly according to claim 1, wherein the base sleeve (9) has an adjustment ring (11) formed integrally at its end opposite the bulb bent out at right angles. The lamp bulb according to claim 1, wherein the base sleeve (9) has several pointed coupling bumps (10) circumferentially distributed therein and a holder element (7) is welded to the bumps. And base assembly.

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